Repackable Muffler

ABSTRACT

A repackable muffler and repackable muffler kit for all terrain vehicles (ATV), dirt bikes, motorcycles and the like are provided. The inlet end cap and exhaust of the muffler are secured using clamps therefore minimizing the time required to repack the muffler.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Application No. 62/379,278, filed Aug. 25, 2016, which is incorporated by reference under 37 C.F.R. §1.57.

FIELD OF THE INVENTION

This invention relates to mufflers and in particular, to a muffler design that facilitates aftermarket repack.

BACKGROUND OF THE INVENTION

Mufflers in all terrain vehicles (ATV), utility task vehicles (UTV), dirt bikes, motorcycles and the like generally include an outer housing or tube (casing) with a double inner perforated tube. The outer housing is generally SAE 304 stainless steel. The space between the outer housing or tube and the inner perforated tube is filled with sound absorbing material or packing, for example, high density, high temperature ceramic fiber.

The packing material over time loses effectiveness and needs replacing. Existing designs of repackable mufflers require removal of rivets that hold the ends on. Wth existing designs, two rivets holding the inlet and outlet caps on are drilled out and the inlet cap removed. The inner perforated tube with associated packing material is then removed. Once removed the packing material is replaced and the muffler reassembled and the inlet cap riveted in place.

This background information is provided for the purpose of making known information believed by the applicant to be of possible relevance to the present invention. No admission is necessarily intended, nor should be construed, that any of the preceding information constitutes prior art against the present invention.

SUMMARY OF THE INVENTION

An object of the present invention is to provide a repackable muffler. In accordance with an aspect of the present invention, there is provided a muffler for a vehicle having an internal combustion engine, the muffler comprising a outer housing having a first end and a second end, each of the first end and second end having a lip, an inner muffler assembly comprising a double inner perforated tube assembly, the inner tube assembly having an inlet end and an outlet end, an inlet annular end cap adapted to receiving exhaust gases connected to the inlet end of the inner tube, the inlet annular end cap comprising a lip or flange and is size such that the lip of the inlet annular end cap and the lip of the first end of the outer housing are generally inline when the inner tube is installed in the outer housing; and packing wrapped around the inner tube between the inlet annular end cap and the outlet annular end cap; a first clamp configured to secure the inlet annular end cap to the first end of the end of outer housing when the inner muffler assembly is positioned in the outer housing; an outlet annular end cap installed on the inner tube proximal to the outlet end; an exhaust pipe with a lip size such that the lip of exhaust and the lip of the second end of the outer housing are generally inline when the exhaust tube is in position; and a second clamp configure to secure the exhaust pipe to the second end of outer housing.

In accordance with another aspect of the invention, there is provided a repackable muffler kit comprising a outer housing having a first end and a second end, each of the first end and second end having a lip, an inner tube assembly having a plurality of holes, the inner tube having an inlet end and an outlet end, an inlet annular end cap adapted to receiving exhaust gases connected to the inlet end of the inner tube, the inlet annular end cap comprising a lip or flange and is size such that the lip of the inlet annular end cap and the lip of the first end of the outer housing are generally inline when the inner tube is installed in the outer housing; a first clamp configured to secure the inlet annular end cap to the first end of the end of outer housing; an outlet annular end cap for installation on the inner tube proximal to the outlet end; a pre-cut packing sheet; an exhaust pipe with a lip size such that the lip of exhaust and the lip of the second end of the outer housing are generally inline when the exhaust tube is in position; a second clamp configure to secure the exhaust pipe to the second end of outer housing, and instructions for use.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features of the invention will become more apparent in the following detailed description in which reference is made to the appended drawings.

FIG. 1 shows a muffler (10) in accordance with one embodiment of the invention showing clamps (12), outer housing (20), inlet annular end cap (22) and exhaust pipe (16).

FIG. 2 is a cross-sectional view of the embodiment of FIG. 1 detailing the inlet annular end cap (22) with lip (23), outer annular cap (24), high density, high temperature ceramic fiber packing (26) and double inner tube assembly (28 a and 28 b), internal baffle (30), clamps (12), and exhaust pipe (16) with lip (34).

FIG. 3 is an exploded view of the embodiment of FIG. 1 detailing the outer housing (20), inlet annular end cap (22) with lip (23), outer annular cap (24), high density, high temperature ceramic fiber packing (26) and double inner tube assembly (28 a and 28 b), internal baffle (30), clamps (12), and exhaust pipe (16) with lip (34).

FIG. 4 is a side-perspective view that shows the adjustable screw bolt clamp (12) of the embodiment shown in FIG. 1.

FIG. 5 is a side view that shows the adjustable screw bolt clamp (12) of the embodiment shown in FIG. 1.

FIG. 6 is a side-perspective view that shows the internal baffle (30) with a plurality of openings (32) to allow exhaust to enter the muffler.

FIG. 7 is a side view that shows the internal baffle (30) with a plurality of openings (32) to allow exhaust to enter the muffler.

FIG. 8 shows high density, high temperature ceramic fiber packing (26) of the embodiment shown in FIG. 1.

FIG. 9 shows the inner muffler assembly detailing inlet annular end cap (22) with lip (23), outer annular cap (24), high density, high temperature ceramic fiber packing (26) and inner tube (partially shown) (28 b) of the embodiment shown in FIG. 1.

FIG. 10 shows one embodiment of the muffler detailing components thereof.

DETAILED DESCRIPTION OF THE INVENTION

This invention provides a repackable muffler for use on all terrain vehicles (ATV), utility task vehicles (UTV), dirt bikes, motorcycles and the like. The repackable muffler is configured to facilitate repacking by limited use of rivets or eliminating the use of rivets. The use of clamps facilitates removal and replacement of the end caps, thereby substantially reducing the amount of time required to repack the muffler.

The muffler may be sold pre-assembled or may be sold as a kit. In some embodiments, the kit includes a pre-assembled muffler and instructions for repacking. Optionally, the kit may also include one or more pre-cut replacement high density, high temperature ceramic fiber. Other optional elements may be included in the kit such as extra nuts for clamp, masking tape, gloves, and high temperature silicone sealer.

Optionally, components of the muffler may be sold individually with instructions for use. The individual sold components include the clamps and pre-cut fiberglass sheets.

Referring to FIGS. 1 to 10, the muffler (10) comprises an outer housing (20) or tube having a first end and second end. Each of the first and second ends includes a lip (21) or flange. In the illustrated embodiment, the lip or flange (21) is continuous round the circumference of the housing. The outer housing or tube has a generally circular cross-section and is manufactured from aluminized steel, stainless steel including SAE 304 stainless steel or other appropriate materials known in the art. The outer housing includes a baffle (30) with a plurality of openings (32) to allow exhaust to enter the muffler. The baffle (30) reduces flow without causing a restriction and may facilitates placement of the inner muffler assembly within the outer housing.

Housed within the outer tube (20) is an inner muffler assembly comprising a double inner tube assembly (28 a and 28 b) having a plurality of holes or perforations with inlet and outlet annular end caps. The inner tube has a generally circular cross-section and is manufactured from aluminized steel, stainless steel or other appropriate materials known in the art.

The inner tube assembly is operatively connected to an inlet annular end cap (22) which is configured for connection to the vehicles exhaust system. In some embodiments, the inner tube is wielded to the inlet end cap (22). The inlet annular end cap (22) includes a lip (23) or flange and is sized such that the lip of the inlet annular end cap and the lip (21) of the inlet end of the outer housing (20) are generally inline when the inner muffler assembly (18) is positioned in the outer housing (20).

In the illustrated embodiment, the inlet annular end cap (22) includes a stepped portion sized to provide a gap between the face of the step portion and the inner tube (28). The gap is sized to accommodate the fiberglass packing (16).

The inner tube assembly is also operatively connected to an outlet annular cap (24). In the illustrated embodiment, the outlet annular cap is generally hemi-spherical with extended straight side which provides a gap sized to accommodate the fiberglass packing (26) between the extended straight side and the inner tube (28). The outlet annular cap is sized to fit into the outer housing (20).

In some embodiments, the outlet annular cap is configured to be positioned at any angle.

The fiberglass packing material is wrapped around the inner tube (28) between the inlet annular end cap (22) and the outlet annular cap (24) and partially secured by the gaps between the end caps and inner tube (28).

The inlet annular end cap (22), outer annular cap (24), fiberglass packing (26) and inner tube assembly form the inner muffler assembly which is positioned into the outer housing (20). The inner muffler assembly is secured in position within the outer housing (20) by clamp (12). In the illustrated embodiment, clamps (12) are adjustable screw bolt clamp configured to engage the lip or flange of the inlet annular end cap (22) and the outer housing (20). A similar clamp secures the exhaust pipe to the outer housing via their respective lips.

In some embodiments, quick release clamps replace one or both of the adjustable screw bolt clamps.

The clamp may be provided with one or more channels (13) sized to accommodate the lip or flanges of the connecting components.

In some embodiments, a single continuous channel is provided on the inner diameter.

Repacking Method:

Referring to FIGS. 1 to 10, to repack the muffler, the clamp securing the inlet end cap to the outer housing is loosened and the clamp optionally removed. Optionally, the clamp securing the exhaust outlet is also loosened and optionally removed allowing for removal of the exhaust pipe.

When the clamp is loosened or removed, the inner muffler assembly is slid out of the outer housing. The old packing material is removed from the inner muffler assembly and inner tube and caps, if necessary, are cleaned for example using a wire brush.

The new fiberglass packing is wrapped evenly around the inner tube as shown in FIG. 9.

The outer housing is slipped over the inner muffler assembly and the clamps secured thereby securing the inner assembly to the outer housing. If the exhaust pipe has been removed it is also reinstalled.

If necessary, high temperature silicon can be used between the inlet cap and the outer housing and/or the exhaust pipe and the outer housing.

Although the invention has been described with reference to certain specific embodiments, various modifications thereof will be apparent to those skilled in the art without departing from the spirit and scope of the invention. All such modifications as would be apparent to one skilled in the art are intended to be included within the scope of the following claims. 

We claim:
 1. A muffler for a vehicle having an internal combustion engine, the muffler comprising: an outer housing having a first end and a second end, each of the first end and the second end having a lip; an outlet annular end cap; an inner muffler assembly comprising: a double inner tube assembly having a plurality of holes, the double inner tube assembly having an inlet end and an outlet end; an inlet annular end cap adapted to receiving exhaust gases connected to the inlet end of the double inner tube assembly, the inlet annular end cap comprising a lip or flange and is sized such that the lip of the inlet annular end cap and the lip of the first end of the outer housing are generally inline when the double inner tube assembly is installed in the outer housing; and packing wrapped around the double inner tube assembly between the inlet annular end cap and the outlet annular end cap; a first clamp configured to secure the inlet annular end cap to the first end of the outer housing when the inner muffler assembly is positioned in the outer housing; an exhaust pipe with a lip size such that the lip of exhaust and the lip of the second end of the outer housing are generally inline when the exhaust tube is in position; and a second clamp configured to secure the exhaust pipe to the second end of outer housing, wherein the outlet annular end cap is installed on the double inner tube assembly proximal to the outlet end.
 2. The muffler of claim 1, wherein the first clamp and the second clamp have one or more channels.
 3. The muffler of claim 2, wherein the first clamp and the second clamp have one channel.
 4. The muffler of claim 1, wherein the first clamp and second clamp are adjustable screw bolt clamps.
 5. The muffler of claim 2, wherein the first clamp and second clamp are adjustable screw bolt clamps.
 6. The muffler of claim 3, wherein the first clamp and second clamp are adjustable screw bolt clamps.
 7. A repackable muffler kit comprising: an outer housing having a first end and a second end, each of the first end and the second end having a lip; a double inner tube assembly having a plurality of holes, the double inner tube assembly having an inlet end and an outlet end; an inlet annular end cap adapted to receiving exhaust gases connected to the inlet end of the double inner tube assembly, the inlet annular end cap comprising a lip or flange and is sized such that the lip of the inlet annular end cap and the lip of the first end of the outer housing are generally inline when the double inner tube assembly is installed in the outer housing; a first clamp configured to secure the inlet annular end cap to the first end of the outer housing; an outlet annular end cap for installation on the double inner tube assembly proximal to the outlet end; a pre-cut packing sheet; an exhaust pipe with a lip size such that the lip of exhaust and the lip of the second end of the outer housing are generally inline when the exhaust tube is in position; a second clamp configured to secure the exhaust pipe to the second end of the outer housing; and instructions for use.
 8. The kit of claim 7, comprising two or more pre-cut packing sheets.
 9. The kit of claim 8, further comprising a pre-assembled muffler. 